IMPROVEDLASERS
Field of the Invention
The general field of the invention is in the improvement of industrial high power lasers for materials processing applications and more specifically provides methods to control the mode of high power lasers using stable resonators to improve their metal cutting and welding performance.
Background of the Invention
In materials processing applications, and particularly in the cutting and welding of metals, the three primary laser characteristics that determine its performance are: the output power, beam quality, beam polarization. As is well known, laser beams with either random or linear polarization do not perform well in metal cutting and welding applications (see, e.g., Ref. 1). Beams with circular polarization typically perform much better (Ref. 1), and therefore the polarization of a laser is often circularized, typically outside of the laser cavity, to improve its metal processing performance. This is necessary since there is no technique known today to produce a circularly polarized beam inside the laser cavity. Furthermore, beams with random polarization cannot be circularly polarized without significant loss of power, and even linearly polarized beams, which are fairly easy to generate and therefore quite common in many lasers, require the addition of extra-cavity optical components (typically - a retardation plate) to produce the desired circular
polarization. Thus the need to circularize the polarization of a laser beam has resulted, so far, in a loss of some optical power and/or required adding some optical components (and cost) to the laser system.
We also refer to our European Patent No.0390 013 Bl, "Laser System1' .
Summary of the Invention
The present invention is based on our discovery that axisymmetric polarized beams can be produced effectively, by following certain techniques described in the following. The novel lasers produce azimuthally or radially polarized beams, optionally with extra- cavity treatment, exhibit excellent materials processing performance.
Description of the Preferred Embodiment
Several techniques were developed to achieve the desired polarization control, both in cylindrical and in annular- lasers. These techniques can be divided into two categories, based on the use of:
a.Polarization selective reflectors and coatings, which are optical elements within the resonator and which reflect different polarizaitions at different intensity and/or percentage.
b.Brewster angle cones, which discriminate between different polarizations.
According to a further feature of this invention it is possible to transform an azimuthally polarized beam to a radially polarized beam and vice versa, by means of:
c.Extra-cavity auxiliary phase retarders
The invention will be described with reference to the enclosed schematical Figures, which are not according to scale and in which:
Fig. 1 is a sectional side view of a laser system of the invention;
Fig. 2 is a sectional side view of another laser of the present invention;
Figures 3a and 3b illustrate mirror arrangements resulting in polarized laser beams.
(a)Two embodiments of this invention are described in Figures 1 and 2.
Figure 1, shows an annular laser system, similar to that described in Ref. 2, corresponding to EP 0 390 013 Bl the laser output beam produced by this configuration in a TEM01. mode, which can be azimuthally polarized or radially polarized or have a polarization which is any combination of the two. By using an uncoated copper axicon, 20, and an uncoated waxicon, 18, a beam that is azimuthally polarized is produced. This is according to
4 the different reflective properties of the copper regarding the P and S linear polarizations. We verified this by using a polarizer/analyzer technique, placing a polarizer in the output beam paths of C02 lasers built essentially along the guidelines of Ref. 3, and recording the beam profile, while turning the polarizer around the beam axis. The output powers of these lasers were 1000W and 1600W. The results were clearly those of azimuthally polarized beams: the polarizer/analyzer extracted from the beam all energy that was polarized perpendicularly to the polarizer axis, leaving a beam profile that is typical of a TEM01 mode, linearly polarized in the polarizer's axis direction. This is consistent with the classical explanation of the TEM01, mode in REF. 4.
Different polarization selective high reflectivity coatings, which are commercially available and have different reflective properties regarding the P and S polarizations, on the waxicon and/or axicon mirrors, produce in the same configuration on Figure 1, a TEM01, mode with a radial or azimuthal polarization. This was verified using the above polarizer/analyzer technique.
In any laser system which produces a beam with TEM01. mode, the polarization can be controlled to be azimuthal or radial, by implementing the above methods and selection of the resonator optics.
(b)Figure 2 shows an annular laser, similar to the configuration in Figure 1, without polarization selective coating, but with an addition of a transparent conical part, 21, (for a C02 laser this part is made of ZnSe or other suitable material). The angle of the cone is the Brewster angle. As a result, the laser will operate with a preferred radial polarization that is also compatible with the TEM01. mode.
The mirror arrangement shown in Figure 3 a (1) comprises a mirror 31 which reflects beam 32 by an angle of 90° and this is incident on mirror 33 which is not in the same plane as mirror 31. The same arrangement, viewed along arrow 34 is shown in Figure 3a(2) where the mirrors are again not in the same plane.
A complimentary system that can be used to convert radial polarization into azimuthal polarization or vice versa is presented schematically in Figure 3a. This utilizes a pair of half-wave phase-retarding mirrors(or plates). The first mirror is mounted at 45° to the beam direction, reflecting it at 90°. The second mirror is mounted at 45° to the direction of the reflected beam, and its plane is not parallel to the plane of the first mirror, but is inclined to it at 45°. A radially polarized beam passing through such arrangement will become azimuthally polarized. Ac ording to Babinet's
Principle, the same arrangement can turn an azimuthally polarized beam into a radially polarized beam.
Another 4-mirror arrangement is illustrated with reference to Figure 3b. As shown in Figure 3b(l) the ray 35 is reflected by mirrors 36, 37, 38 and 39 as shown. The same mirrors are illustrated in Figure 3b(2), where the angle between mirrors 36 and 37 is equivalent to that of mirror 31 of Figure 3a(l), and mirrors 38 and 39 are the equivalent of mirror 33 of Figure 3a( 1) .
Figure 3b depicts an alternative arrangement to achieve the same polarization conversion, that utilizes a pair of quarter-wave phase retarder instead of each single half-wave retarder. The advantage of this arrangement over the former one is that the beam exists in a direction parallel to the original beam direction.
This was verified using a polarizer/analyzer technique, as mentioned above, without and with an optical setup, similar to the configuration in figure 3b. The results show clearly that there is complete conversion of the polarization.
The system and methods described differ significantly from the well-known systems and methods whereby linear polarization that can be generated in other industrial lasers is converted into a circular polarization. In
7 the present invention, the polarization is axisymmetric, either azimuthal or radial.
The necessity to create an axisymmetric polarized beam stems from the requirement of homogenous material processing in all directions. The capability to generate laser beams with time-constant axisymmetric polarizations enables their judicious usage to optimize different industrial applications, such as high- quality, high-speed cutting of highly-reflective materials, deep penetration welding etc. Specifically, excellent cutting speeds and quality have been achieved with bare aluminum and bare copper, as well as with mild steel and stainless steel. Also, butt welding in stainless steel has been achieved with deeper penetration and higher speeds than was reported for other lasers with similar power, which did not have either azimuthal or radial polarization.
It is clear that the above description is by way of illustration only and is not to be construed in a limitative manner.
References:
l.C02 Laser Cutting, by John Powell, Springer-Verlag London Limited, 1993.
2.European Patent No. 0 390 013 Bl, granted June 1, 1994.
3.Annular (HSURIA) resonators: some experimental studies including polarization effects: R.A. Chodzko, S.B. Mason, E.B. Turner, W.W. Plummer, Jr. Applied Optics, Vol. 19, No.5, pp. 778-789, March 1980.
4. asers, by A.E. Sigman, Copyright© University
Science Books, 1986.